Thermoplastic sheets and articles with variable lofting capacity

ABSTRACT

Certain configurations are described herein of a thermoplastic sheet or article comprising a plurality of porous layers coupled to each other. In one configuration, the thermoplastic article may comprise a core layer, a first layer disposed on one surface of the core layer and a second layer disposed on another surface of the core layer. In some instances, each of the core layer, the first layer and the second layer may comprises a web of open celled structures formed by a plurality of reinforcing materials bonded together with a thermoplastic material and optionally may also include a lofting agent. The lofting capacity in different layers can be selected or tuned to provide desired properties.

PRIORITY APPLICATION

This application is related to, and claims priority to and the benefitof, U.S. Application No. 62/199,767 filed on Jul. 31, 2015, the entiredisclosure of which is hereby incorporated herein by reference for allpurposes.

TECHNOLOGICAL FIELD

This application is related to thermoplastic sheets and articles withvariable lofting capacity. More particularly, certain embodimentsdescribed herein are directed to multi-layer articles with differentlofting capacities in different layers.

BACKGROUND

Articles for automotive and construction materials applicationstypically are designed to meet a number of competing and stringentperformance specifications.

SUMMARY

Certain configurations are described herein that are directed tomulti-layer assemblies, and components thereof, that provide forvariable lofting capacity in different layers. While certain specificconfigurations are described in detail below, the variable loftingcapacity may arise from one or more of a thermoplastic material and/orreinforcing materials. In some instances, lofting capacity can befurther tuned or selected by including an added lofting agent inaddition to the thermoplastic material and/or reinforcing materialspresent in the layer.

In one aspect, a thermoplastic sheet comprising a core layer comprisinga web of open celled structures formed by a plurality of reinforcingmaterials bonded together with a thermoplastic material, the core layerfurther comprising a lofting agent, the core layer also comprising afirst surface and a second surface opposite the first surface, a firstlayer disposed on the first surface of the core layer, the first layercomprising a web of open celled structures formed by a plurality ofreinforcing materials bonded together with a thermoplastic material, anda second layer disposed on the second surface of the core layer, thesecond layer comprising a web of open celled structures formed by aplurality of reinforcing materials bonded together with a thermoplasticmaterial is provided.

In certain embodiments, a basis weight of the first layer issubstantially the same (or different) as a basis weight of the secondlayer. In other configurations, a basis weight of the core layer isgreater than the basis weight of the first layer and greater than thebasis weight of the second layer. In certain instances, the reinforcingmaterials of the first layer, the second layer and the core layer eachcomprise reinforcing fibers. In some examples, the first layer comprisesat least one different reinforcing fiber material than the reinforcingfiber materials of the core layer. In other examples, the reinforcingfibers of the first layer, the second layer and the core layer compriseat least one common reinforcing fiber material. In certain embodiments,the thermoplastic material in the core layer is different than thethermoplastic material in the first layer. In some examples, thethermoplastic material in the first layer and the second layer are thesame. In other examples, the reinforcing materials in the first layerand the second layer are the same. In some instances, the reinforcingmaterials in the first layer and the second layer are the different. Incertain examples, the reinforcing materials of the first layer, thesecond layer and the core layer each comprise reinforcing fibers. Insome examples, the first layer comprises at least one differentreinforcing fiber than the reinforcing fibers of the core layer. Incertain embodiments, the reinforcing fibers of the first layer, thesecond layer and the core layer comprise at least one common reinforcingfiber type. In other embodiments, the lofting agent of the core layercomprises at least one of expandable microspheres and expandablegraphite materials. In some examples, no lofting agent is present in thefirst layer or in the second layer. In other examples, the thermoplasticmaterial and reinforcing materials of the first layer and the secondlayer are selected to permit lofting of the first layer and the secondlayer. In certain embodiments, the thermoplastic material andreinforcing materials of the first layer and second layer permit loftingof the first layer and the second layer at a different loftingtemperature than a lofting temperature used to loft the core layer. Insome examples, the sheet further comprises a first adhesive layerdisposed on the first surface of the core layer between the first layerand the core layer. In other examples, the sheet further comprises asecond adhesive layer disposed on the second surface of the core layerbetween the second layer and the core layer. In some embodiments, thefirst layer is directly disposed on the first adhesive layer and thesecond layer is directly disposed on the second adhesive layer, in whichthe first adhesive layer is directly disposed on the first surface ofthe core layer and in which the second adhesive layer is directlydisposed on the second surface of the core layer. In certainconfigurations, the thermoplastic material of each of the core layer,the first layer and the second layer is independently selected from thegroup consisting of a polyolefin material, a thermoplastic polyolefinblend material, a polyvinyl polymer material, a butadiene polymermaterial, an acrylic polymer material, a polyamide material, a polyestermaterial, a polycarbonate material, a polyestercarbonate material, apolystyrene material, an acrylonitrylstyrene polymer material, anacrylonitrile-butylacrylate-styrene polymer material, a polyether imidematerial, a polyphenylene ether material, a polyphenylene oxidematerial, a polyphenylenesulphide material, a polyether material, apolyetherketone material, a polyacetal material, a polyurethanematerial, a polybenzimidazole material, and copolymers and mixturesthereof. In some embodiments, the thermoplastic material in each of thecore layer, the first layer and the second layer is independently aresin or a fiber. In other embodiments, the reinforcing materials ofeach of the core layer, the first layer and the second layer isindependently selected from the group consisting of glass fibers, carbonfibers, graphite fibers, synthetic organic fibers, inorganic fibers,natural fibers, mineral fibers, metal fibers, metalized inorganicfibers, metalized synthetic fibers, ceramic fibers, and combinationsthereof. In certain examples, the fibers present in each of the corelayer, the first layer and the second layer comprise a diameter greaterthan about 5 microns and a length from about 5 mm to about 200 mm. Inother examples, the sheet comprises a skin layer disposed on the firstlayer. In some examples, the skin layer comprises a fabric, a scrim, afilm and combinations thereof. In other examples, the sheet comprises anadditional skin layer disposed on the second layer. In certainconfigurations, the additional skin layer comprises a fabric, a scrim, afilm and combinations thereof. In some configurations, the thermoplasticmaterial present in each of the core layer, the first layer and thesecond layer comprises a polypropylene, the reinforcing materialspresent in each of the core layer, the first layer and the second layerare glass fibers and the lofting agent of the core layer comprisesexpandable microspheres. In other configurations, the basis weight ofeach of the first and second layers is about 500 gsm to about 3000 gsmand the basis weight of the core layer is about 500 gsm to about 1600gsm.

In an additional aspect, a vehicle load floor that provides structuralreinforcement is provided. In certain configurations, the vehicle loadfloor comprises a core layer comprising a web of open celled structuresformed by a plurality of reinforcing materials bonded together with athermoplastic material, the core layer further comprising a loftingagent, the core layer also comprising a first surface and a secondsurface opposite the first surface, a first layer disposed on the firstsurface of the core layer, the first layer comprising a web of opencelled structures formed by a plurality of reinforcing materials bondedtogether with a thermoplastic material, and a second layer disposed onthe second surface of the core layer, the second layer comprising a webof open celled structures formed by a plurality of reinforcing materialsbonded together with a thermoplastic material, in which the core layer,the first layer and the second layer together provide a vehicle loadfloor that deflects less than about 25 mm at a weight of no more than220 kg, e.g., 200-200 kg.

In certain embodiments, the load floor comprises a decorative layercoupled to the first layer. In some examples, the decorative layercomprises a carpet. In certain examples, the load floor comprises anadhesive layer between the decorative layer and the first layer. Inadditional examples, the load floor comprises a second decorative layercoupled to the second layer. In some examples, the second decorativelayer comprises a carpet. In certain examples, the load floor comprisesan adhesive layer between the second decorative layer and the secondlayer. In certain examples, the load floor deflects less than about 15mm at 100 kg weight, or less than about 15 mm at 150 kg weight, or lessthan about 10 mm at 100 kg weight, or less than about 5 mm at 220 kgweight. In some embodiments, the thermoplastic material of the corelayer comprises at least one similar or different thermoplastic materialthan the thermoplastic material present in the first layer. In certainexamples, the core layer, the first layer and the second layer eachcomprises a void content of at least 5%. In some embodiments, thethermoplastic material of each of the core layer, the first layer andthe second layer is independently selected from the group consisting ofa polyolefin material, a thermoplastic polyolefin blend material, apolyvinyl polymer material, a butadiene polymer material, an acrylicpolymer material, a polyamide material, a polyester material, apolycarbonate material, a polyestercarbonate material, a polystyrenematerial, an acrylonitrylstyrene polymer material, anacrylonitrile-butylacrylate-styrene polymer material, a polyether imidematerial, a polyphenylene ether material, a polyphenylene oxidematerial, a polyphenylenesulphide material, a polyether material, apolyetherketone material, a polyacetal material, a polyurethanematerial, a polybenzimidazole material, and copolymers and mixturesthereof. In certain examples, the thermoplastic material in each of thecore layer, the first layer and the second layer is independently aresin or a fiber. In some embodiments, the reinforcing materials of eachof the core layer, the first layer and the second layer is independentlyselected from the group consisting of glass fibers, carbon fibers,graphite fibers, synthetic organic fibers, inorganic fibers, naturalfibers, mineral fibers, metal fibers, metalized inorganic fibers,metalized synthetic fibers, ceramic fibers, and combinations thereof. Incertain examples, the fibers present in each of the core layer, thefirst layer and the second layer comprise a diameter greater than about5 microns and a length from about 5 mm to about 200 mm. In someembodiments, the thermoplastic material present in each of the corelayer, the first layer and the second layer comprises a polypropylene,and the reinforcing materials present in each of the core layer, thefirst layer and the second layer are glass fibers. In certain examples,the basis weight of each of the first and second layers is about 500 gsmto about 3000 gsm and the basis weight of the core layer is about 500gsm to about 1600 gsm. In some examples, the lofting agent of the corelayer comprises expandable microspheres or expandable graphitematerials. In certain embodiments, the load floor comprises a carpetlayer disposed on at least one of the first layer and the second layer.In some examples, the first layer is coupled to the core layer throughan adhesive layer and the second layer is coupled to the core layerthrough an adhesive layer. In other examples, the first layer and thesecond layer do not include any lofting agent, and wherein thethermoplastic material and reinforcing materials of the first layer andthe second layer are each selected to permit lofting of the first layerand the second layer in the absence of lofting agent in the first layerand the second layer.

In another aspect, a kit for producing a vehicle load floor, the kitcomprising a core layer comprising a web of open celled structuresformed by a plurality of reinforcing materials bonded together with athermoplastic material, the core layer further comprising a loftingagent, the core layer also comprising a first surface and a secondsurface opposite the first surface, a first layer separate from the corelayer and comprising a web of open celled structures formed by aplurality of reinforcing materials bonded together with a thermoplasticmaterial, and a second layer separate from the core layer and the firstlayer and comprising a web of open celled structures formed by aplurality of reinforcing materials bonded together with a thermoplasticmaterial, and instructions for coupling the first layer to the firstsurface of the core layer and for coupling the second layer to thesecond surface of the core layer is described.

In certain embodiments, the kit comprises a decorative layer separatefrom the core layer, the first layer, and the second layer. In someexamples, the kit comprises an adhesive material effective to bond thefirst layer to the core layer. In certain examples, the first layer ofthe kit is the same as the second layer of the kit. In some examples,the kit comprises a skin layer. In some examples, the skin layer isselected from the group consisting of a fabric, a scrim, a film andcombinations thereof. In certain embodiments, the kit comprises a secondcore layer, in which the second core layer comprises a web of opencelled structures formed by a plurality of reinforcing materials bondedtogether with a thermoplastic material, the core layer furthercomprising a lofting agent, the core layer also comprising a firstsurface and a second surface opposite the first surface. In someexamples, the lofting agent of the core layer is different than thelofting agent of the second core layer. In certain examples, the firstcore layer and the second core layer comprise the same thermoplasticmaterial, reinforcing materials and lofting agent. In other embodiments,the basis weight of the core layer is different than the basis weight ofthe second core layer.

In another aspect, a method of forming a thermoplastic sheet comprisingforming a core layer by combining a thermoplastic polymer, reinforcingfibers and a lofting agent in an aqueous solution, mixing the aqueoussolution comprising the thermoplastic polymer, reinforcing fibers andlofting agent to disperse the reinforcing fibers and the lofting agentin the thermoplastic polymer to provide an aqueous foam dispersion,disposing the aqueous foam dispersion onto a forming element, removingliquid from the disposed aqueous foam to provide a core layer comprisinga web comprising the thermoplastic polymer, the reinforcing fibers andthe lofting agent, forming a first layer by combining a thermoplasticpolymer, reinforcing fibers and a lofting agent in an aqueous solution,mixing the aqueous solution comprising the thermoplastic polymer,reinforcing fibers and lofting agent to disperse the reinforcing fibersand the lofting agent in the thermoplastic polymer to provide an aqueousfoam dispersion, disposing the aqueous foam dispersion onto a formingelement, removing liquid from the disposed aqueous foam to provide afirst layer comprising a web comprising the thermoplastic polymer, thereinforcing fibers and the lofting agent, disposing the formed firstlayer on a first surface of the core layer, and disposing another firstlayer on a second surface of the core layer to provide a thermoplasticsheet is disclosed.

In certain embodiments, the method comprises heating the core layerabove a softening temperature of the thermoplastic polymer of the web ofthe core layer prior to disposing the first layer on the first surfaceof the core layer. In other embodiments, the method comprises heatingthe core layer above a softening temperature of the thermoplasticpolymer of the web of the core layer prior to disposing the first layeron the second surface of the core layer. In some examples, the methodcomprises disposing an adhesive layer on the first surface of the corelayer prior to disposing the first layer on the first surface. Incertain embodiments, the method comprises disposing an adhesive layer onthe first layer prior to disposing the first layer on the first surface.In some examples, the method comprises disposing an adhesive layer onthe second surface of the core layer prior to disposing the first layeron the second surface. In certain examples, the method comprisesdisposing an adhesive layer on the first layer prior to disposing thefirst layer on the second surface. In some examples, the methodcomprises heating the thermoplastic sheet to loft each of the core layerand the first layers. In certain embodiments, the method comprisesselecting a first loft temperature to loft the first layers where thefirst layer lacks any lofting agent. In some examples, the methodcomprises selecting a second loft temperature to loft the core layer. Incertain embodiments, the method comprises selecting the first lofttemperature to loft the first layer without any substantial loft of thecore layer. In other embodiments, the method comprises disposing adecorative layer on one of the first layers. In certain examples, themethod comprises lofting the first layers disposed on the core layerusing radiant heating or conduction heating. In certain embodiments, themethod comprises lofting the core layer using infrared heating. In someexamples, the method comprises compressing the thermoplastic sheet toreduce its overall thickness. In some embodiments, the method comprisesmolding the compressed thermoplastic sheet. In certain examples, themethod comprises compressing the core layer prior to disposing the firstlayers on the core layer. In certain examples, the method comprisescompressing the first layers prior to disposing the first layers on thecore layer. In some examples, the method comprises disposing a skinlayer on the first layer disposed on the first surface of the corelayer. In certain embodiments, the method comprises disposing anadditional skin layer on the first layer disposed on the second surfaceof the core layer.

In an additional aspect, a method of forming a thermoplastic sheetcomprising forming a core layer by combining a thermoplastic polymer,reinforcing fibers and a lofting agent in an aqueous solution, mixingthe aqueous solution comprising the thermoplastic polymer, reinforcingfibers and lofting agent to disperse the reinforcing fibers and thelofting agent in the thermoplastic polymer to provide an aqueous foamdispersion, disposing the aqueous foam dispersion onto a formingelement, removing liquid from the disposed aqueous foam to provide acore layer comprising a web comprising the thermoplastic polymer, thereinforcing fibers and the lofting agent, forming each of a first layerand a second layer by combining a thermoplastic polymer, reinforcingfibers and a lofting agent in an aqueous solution, mixing the aqueoussolution comprising the thermoplastic polymer, reinforcing fibers andlofting agent to disperse the reinforcing fibers and the lofting agentin the thermoplastic polymer to provide an aqueous foam dispersion,disposing the aqueous foam dispersion onto a forming element, removingliquid from the disposed aqueous foam to provide a first layercomprising a web comprising the thermoplastic polymer, the reinforcingfibers and the lofting agent, disposing the formed first layer on afirst surface of the core layer, and disposing the formed second layeron a second surface of the core layer to provide a thermoplastic sheetis provided.

In certain embodiments, the method comprises heating the core layerabove a softening temperature of the thermoplastic polymer of the web ofthe core layer prior to disposing the first layer on the first surfaceof the core layer. In some examples, the method comprises heating thecore layer above a softening temperature of the thermoplastic polymer ofthe web of the core layer prior to disposing the second layer on thesecond surface of the core layer. In certain examples, the methodcomprises disposing an adhesive layer on the first surface of the corelayer prior to disposing the first layer on the first surface. In someembodiments, the method comprises disposing an adhesive layer on thefirst layer prior to disposing the first layer on the first surface. Insome embodiments, the method comprises disposing an adhesive layer onthe second surface of the core layer prior to disposing the second layeron the second surface. In some examples, the method comprises disposingan adhesive layer on the second layer prior to disposing the secondlayer on the second surface. In certain examples, the method comprisesheating the thermoplastic sheet to loft each of the core layer and thefirst layers. In some embodiments, the method comprises selecting afirst loft temperature to loft the first layers where the first layerlacks any lofting agent. In certain examples, the method comprisesselecting a second loft temperature to loft the core layer.

In another aspect, a method of forming a thermoplastic sheet comprisingforming a core layer by combining a thermoplastic polymer, reinforcingfibers and a lofting agent in an aqueous solution, mixing the aqueoussolution comprising the thermoplastic polymer, reinforcing fibers andlofting agent to disperse the reinforcing fibers and the lofting agentin the thermoplastic polymer to provide an aqueous foam dispersion,disposing the aqueous foam dispersion onto a forming element, removingliquid from the disposed aqueous foam to provide a core layer comprisinga web comprising the thermoplastic polymer, the reinforcing fibers andthe lofting agent, disposing a first layer on a first surface of thecore layer, the first layer comprising a web of open celled structuresformed by a plurality of reinforcing materials bonded together with athermoplastic material, and disposing a second layer on a second surfaceof the core layer, the second layer comprising a web of open celledstructures formed by a plurality of reinforcing materials bondedtogether with a thermoplastic material is disclosed.

In certain embodiments, the method comprises heating the core layerabove a softening temperature of the thermoplastic polymer of the web ofthe core layer prior to disposing the first layer on the first surfaceof the core layer. In some embodiments, the method comprises heating thecore layer above a softening temperature of the thermoplastic polymer ofthe web of the core layer prior to disposing the second layer on thesecond surface of the core layer. In some examples, the method comprisesdisposing an adhesive layer on the first surface of the core layer priorto disposing the first layer on the first surface. In certain examples,the method comprises disposing an adhesive layer on the first layerprior to disposing the first layer on the first surface. In someembodiments, the method comprises disposing an adhesive layer on thesecond surface of the core layer prior to disposing the second layer onthe second surface. In certain examples, disposing an adhesive layer onthe second layer prior to disposing the second layer on the secondsurface. In certain embodiments, the method comprises heating thethermoplastic sheet to loft each of the core layer and the first layers.In some examples, the method comprises selecting a first lofttemperature to loft the first layers where the first layer lacks anylofting agent. In certain embodiments, the method comprises selecting asecond loft temperature to loft the core layer.

Additional features, aspect, examples, configurations and embodimentsare described in more detail below.

BRIEF DESCRIPTION OF THE FIGURES

Certain embodiments are described with reference to the accompanyingfigures in which:

FIG. 1 is an illustration of a multi-layer assembly, in accordance withcertain examples;

FIG. 2 is an illustration of a multi-layer assembly including a corelayer with a high lofting capacity, in accordance with certain examples;

FIG. 3 is an illustration of a multi-layer assembly including a corelayer with a low lofting capacity, in accordance with certain examples;

FIG. 4 is an illustration of a multi-layer assembly including threelayers each with a different lofting capacity, in accordance withcertain examples;

FIG. 5A is an illustration of a multi-layer assembly comprising a skinon one surface, in accordance with certain configurations;

FIG. 5B is an illustration of a multi-layer assembly comprising a skinon each surface, in accordance with certain configurations;

FIG. 6 is an illustration of a multi-layer assembly comprising adecorative layer on an outer surface, in accordance with certainexamples;

FIG. 7 is an illustration of an article comprising four layers, inaccordance with certain examples;

FIG. 8 is an illustration of another article comprising four layers, inaccordance with certain examples;

FIG. 9 is an illustration of an article comprising five layers, inaccordance with certain configurations;

FIG. 10 is an illustration of a vehicle floor, in accordance withcertain examples; and

FIG. 11 is an illustration of a load floor, in accordance with certainconfigurations.

It will be recognized by the person of ordinary skill in the art, giventhe benefit of this disclosure, that certain dimensions or features inthe figures may have been enlarged, distorted or shown in an otherwiseunconventional or non-proportional manner to provide a more userfriendly version of the figures. No particular thickness, width orlength is intended by the depictions in the figures, and relative sizesof the figure components are not intended to limit the sizes of any ofthe components in the figures. Where dimensions or values are specifiedin the description below, the dimensions or values are provided forillustrative purposes only. In addition, no particular material orarrangement is intended to be required by virtue of shading of certainportions of the figures, and even though different components in thefigures may include shading for purposes of distinction, the differentcomponents can include the same or similar materials, if desired.

DETAILED DESCRIPTION

Certain embodiments are described below with reference to singular andplural terms in order to provide a more user friendly description of thetechnology disclosed herein. These terms are used for conveniencepurposes only and are not intended to limit the layers, assemblies,articles, methods and other subject matter as including or excludingcertain features unless otherwise noted as being present in a particularembodiment described herein.

In certain instances, the materials described herein can be usedtogether to provide sheets, panels, floor pans, load floors and otherarticles. For example, the multi-layer assembly can be used as a wall orceiling panel, as flooring, a sub-floor or in automotive applicationssuch as, for example, vehicle load floors or underbody floors of avehicle. Where the assembly is used as a vehicle load floor, the loadfloor may be present as an underbody assembly within the vehicle cabinor may be present as or in one or more different components or areas ofthe vehicle, e.g., as a drawn load floor in a vehicle storagecompartment in the rear of a vehicle. As noted herein, someconfigurations of the multi-layer assembly may be produced without theuse of any cellulose or paper based materials. In other instances, themulti-layer assembly may be produced without the use of any polyurethanecore component or without the use of any polyurethane whatsoever.

In certain configurations, the multi-layer assembly may comprise threeor more different layers coupled to each other with one of the layerscomprising a different lofting capacity than the other layers. Referringto FIG. 1, a three layer assembly 100 is shown that comprises layers110, 120, and 130. The layer 110 is referred to in certain instances asa “core layer” as it is present between the two layers 120, 130. Variousphysical properties of the layers 110-130 may be the same or may bedifferent. For example, the basis weight of any two of the layers110-130 may be the same or may be different. In other instances, theoverall thickness of the layers 110-130 may be the same or may bedifferent. As described in more detail below, each of the layers 110-130may comprise a thermoplastic material and/or a plurality of reinforcingmaterials, e.g., reinforcing fibers. By selecting the amount and/ornature of these materials to be different in two or more of the layers110-130, the lofting capacity of the layers can be varied in thedifferent layers, e.g., the assembly 100 has a variable lofting capacityin different layers. As used herein, lofting capacity refers to theability to increase the overall thickness of the layer after applicationof a suitable stimulus such as heating. The ability to control or selectthe lofting capacity in each layer can provide for an assembly withreduced weight and with suitable structural rigidity and mechanicalproperties that can be used as panels, floor assemblies or sub floorassemblies.

In certain embodiments, any one or more of the layers 110-130 may beconfigured as (or used in) a glass mat thermoplastic composite (GMT) ora light weight reinforced thermoplastic (LWRT). One such LWRT isprepared by HANWHA AZDEL, Inc. and sold under the trademark SUPERLITE®mat. The areal density of such a GMT or LWRT can range from about 400grams per square meter (gsm) of the GMT or LWRT to about 4000 gsm,although the areal density may be less than 400 gsm or greater than 4000gsm depending on the specific application needs. In some embodiments,the upper density can be less than about 4000 gsm. In certain instances,the GMT or the LWRT may comprise lofting agent material disposed in voidspace of the GMT or the LWRT.

In certain examples, the LWRT typically includes a thermoplasticmaterial and a plurality of reinforcing fibers which together form a webof open celled structures. For example, each of the layers 110-130typically comprises a substantial amount of open cell structure suchthat void space is present in the layers. For example, each of thelayers may independently comprise a void content or porosity of 0-30%,10-40%, 20-50%, 30-60%, 40-70%, 50-80%, 60-90%, 0-40%, 0-50%, 0-60%,0-70%, 0-80%, 0-90%, 10-50%, 10-60%, 10-70%, 10-80%, 10-90%, 10-95%,20-60%, 20-70%, 20-80%, 20-90%, 20-95%, 30-70%, 30-80%, 30-90%, 30-95%,40-80%, 40-90%, 40-95%, 50-90%, 50-95%, 60-95% 70-80%, 70-90%, 70-95%,80-90%, 80-95% or any illustrative value within these exemplary ranges.In some instances, each of the layers 110-130 comprises a porosity orvoid content of greater than 0%, e.g., is not fully consolidated, up toabout 95%. Unless otherwise stated, the reference to the layercomprising a certain void content or porosity is based on the totalvolume of the layer and not necessarily the total volume of themulti-layer assembly.

In certain examples, one or more of the layers 110-130 can be producedin the form of a GMT. In certain instances, the GMT can be generallyprepared using chopped glass fibers, a thermoplastic material,optionally a lofting agent and an optional thermoplastic polymer film orfilms and/or woven or non-woven fabrics made with glass fibers orthermoplastic resin fibers such as, for example, polypropylene (PP),polybutylene terephthalate (PBT), polyethylene terephthalate (PET),polycarbonate (PC), a blend of PC/PBT, or a blend of PC/PET. In someembodiments, a PP, a PBT, a PET, a PC/PET blend or a PC/PBT blend can beused as a resin. To produce the glass mat, a thermoplastic material andreinforcing materials can be added or metered into a dispersing foamcontained in an open top mixing tank fitted with an impeller. Withoutwishing to be bound by any particular theory, the presence of trappedpockets of air of the foam can assist in dispersing the glass fibers,the thermoplastic material and the lofting agent. In some examples, thedispersed mixture of fibers and thermoplastic material can be pumped toa head-box located above a wire section of a paper machine via adistribution manifold. The foam, not the fibers and thermoplastic, canthen be removed as the dispersed mixture is provided to a moving wirescreen using a vacuum, continuously producing a uniform, fibrous wetweb. The wet web can be passed through a dryer at a suitable temperatureto reduce moisture content and to melt or soften the thermoplasticmaterial.

In certain embodiments, the high porosity present in the layers 110-130can reduce the overall weight of the layers and can permit the inclusionof agents within the void space. For example, lofting agents can residein the void space in a non-covalently bonded manner. Application of heator other perturbations can act to increase the volume of thenon-covalently bonded lofting agent which in turn increases the overallthickness of the layer, e.g., the layer increases as the size of thelofting agent increases and/or additional air becomes trapped in theprepreg. If desired, flame retardants, colorants, smoke suppressants andother materials may be included in the void space of the layers 110-130.Prior to lofting, any one or more of the layers 110-130 can becompressed to reduce its overall thickness, e.g., compressed before orafter the layer is coupled to one or more other layers.

In certain embodiments, the thermoplastic material of the layersdescribed herein may comprise, at least in part, one or more ofpolyethylene, polypropylene, polystyrene, acrylonitrylstyrene,butadiene, polyethyleneterephthalate, polybutyleneterephthalate,polybutylenetetrachlorate, and polyvinyl chloride, both plasticized andunplasticized, and blends of these materials with each other or otherpolymeric materials. Other suitable thermoplastics include, but are notlimited to, polyarylene ethers, polycarbonates, polyestercarbonates,thermoplastic polyesters, polyimides, polyetherimides, polyamides,acrylonitrile-butylacrylate-styrene polymers, amorphous nylon,polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone,polyether sulfone, liquid crystalline polymers, poly(1,4 phenylene)compounds commercially known as PARMAX®, high heat polycarbonate such asBayer's APEC® PC, high temperature nylon, and silicones, as well ascopolymers, alloys and blends of these materials with each other orother polymeric materials. The thermoplastic material used to form thelayers 110-130 can be used in powder form, resin form, rosin form, fiberform or other suitable forms. Illustrative thermoplastic materials invarious forms are described herein and are also described, for examplein U.S. Publication Nos. 20130244528 and US20120065283. The exact amountof thermoplastic material present in the layers 110-130 can vary andillustrative amounts range from about 20% by weight to about 80% byweight, e.g., 30-70 percent by weight or 35-65 percent by weight. Asnoted in more detail herein, by varying the chemical composition (and/oramount) of the thermoplastic material in the different layers 110-130,the different layers 110-130 may provide for different loftingcapacities even where no added lofting agent is present in the layers110-130.

In certain embodiments, a thermoplastic material used in one of thelayers 110-130 differs chemically from a thermoplastic material used inthe other layers. For example, the thermoplastic material present in thelayer 110 may differ chemically than the thermoplastic material presentin the layer 120 or the layer 130 or both. In some instances, thethermoplastic material present in the layers 120, 130 may be the same,and the thermoplastic material present in the layer 110 may bedifferent. In certain configurations, the thermoplastic material presentin the layers 110-130 each may be chemically different. By selecting thethermoplastic material present in the layers 110-130, it is possible toprovide layers with differing lofting capacities. Even though adifferent thermoplastic material may be present in one or more of thelayers 110-130, one or more common materials may also be present in thelayers 110-130. For example, the layers 110-130 may each comprise afirst polyolefin and the layers 120, 130 may also comprise a secondpolyolefin not present in the first layer 110.

In other embodiments, a thermoplastic material used in one of the layers110-130 may be chemically the same as a thermoplastic material presentin another one of the layers, but the amount of the thermoplasticmaterial may be different. For example, the layer 110 may comprise afirst thermoplastic material present in a first amount (by weight) thatis different than the amount of the first thermoplastic material presentin one of the other layers 120, 130. The balance of the materials in thelayers may comprise reinforcing fibers (as discussed below) or maycomprise other materials such as, for example, another thermoplasticmaterial, a lofting agent, a flame retardant or other materials asdesired. Without wishing to be bound by any particular theory, byselecting the amount of a particular thermoplastic material present in alayer, the overall volume of the web of open celled structures can bechanged.

In certain examples, the reinforcing materials of the layers 110-130described herein can independently comprise glass fibers, carbon fibers,graphite fibers, synthetic organic fibers, particularly high modulusorganic fibers such as, for example, para- and meta-aramid fibers, nylonfibers, polyester fibers, or any of the high melt flow index resinsdescribed herein that are suitable for use as fibers, mineral fiberssuch as basalt, mineral wool (e.g., rock or slag wool), wollastonite,alumina silica, and the like, or mixtures thereof, metal fibers,metalized natural and/or synthetic fibers, ceramic fibers, yarn fibers,or mixtures thereof. In some embodiments, any of the aforementionedfibers can be chemically treated prior to use to provide desiredfunctional groups or to impart other physical properties to the fibers,e.g., may be chemically treated so that they can react with thethermoplastic material, the lofting agent or both. The fiber content ineach of the layers 110-130 may independently be from about 20% to about90% by weight of the layer, more particularly from about 30% to about70%, by weight of the layer. Typically, the fiber content of amulti-layer assembly comprising the layers 110-130 varies between about20% to about 90% by weight, more particularly about 30% by weight toabout 80% by weight, e.g., about 40% to about 70% by weight of theassembly. The particular size and/or orientation of the fibers used maydepend, at least in part, on the thermoplastic polymer material usedand/or the desired properties of the resulting layers 110-130. Suitableadditional types of fibers, fiber sizes and amounts will be readilyselected by the person of ordinary skill in the art, given the benefitof this disclosure. In one non-limiting illustration, fibers dispersedwithin a thermoplastic material and lofting agent to provide a layer cangenerally have a diameter of greater than about 5 microns, moreparticularly from about 5 microns to about 22 microns, and a length offrom about 5 mm to about 200 mm; more particularly, the fiber diametermay be from about microns to about 22 microns and the fiber length maybe from about 5 mm to about 75 mm.

In certain embodiments, at least two of the layers 110-130 may comprisea different fiber material or a different fiber loading. Where differentfiber materials are present, the fibers may be different fibersentirely, e.g., glass fibers in one layer and carbon fibers in anotherlayer, or may comprise the same base material that has been modified,e.g., glass fibers in one layer and chemically treated glass fibers inanother layer. In some instances, the fibers may be the same fibermaterial but one or more physical properties of the fibers may differ.For example, the fibers of the layer 110 may have a first diameter thatdiffers from a diameter of the fibers present in the layer 120 eventhough the fiber material in the layers 110, 120 may be the same ordifferent. In other instances, the length of the fibers in the layer 110may differ from a length of the fibers present in the layer 120 eventhough the fiber material present in the layers 110, 120 may be the sameor different. In additional examples, both the length and diameter ofthe fiber in the layer 110 may differ from a length and diameter of thefibers in the layer 120 even though the fiber material present in thelayers 110, 120 may be the same or different. In yet other examples, twoor more fiber types may be used in one of the layers 110, 120 and asingle type of fibers may be present in the other layer. As notedherein, by selecting the amount and/or type of fibers, it is possible toprovide a different lofting capacity for different layers of theassembly.

In certain embodiments, two or more of the layers 110-130 may have adifferent lofting profile. For example, in some instances, the layer 110may loft at a different temperature than the layer 120. In otherexamples, the layer 110 may loft at a different temperature than thelayer 130. In further configurations, two or more of the layers 110-130may loft at the same temperature but the degree to which they loft maybe different, e.g., the post-loft thickness of one of the layers 110-130may be different than a post-loft thickness of one of the other layerseven though all the layers are subjected to the same loftingtemperature.

In some embodiments, the lofting capacity of the various layers 110-130can be further tuned by including one or more added lofting agents. Theexact type of lofting agent used in the layer can depend on numerousfactors including, for example, the desired lofting temperature, thedesired degree of loft, etc. In some instances, microsphere loftingagents, e.g., expandable microspheres, which can increase their sizeupon exposure to convection heating may be used. Illustrativecommercially available lofting agents are available from Kureha Corp.(Japan). In other instances, a first lofting agent with a first averageparticle size and a second lofting agent with a second average particlesize, different from the first average particle size, may be used. Inother examples, the lofting agent may be an expandable graphitematerial.

In some configurations, each of the layers 110-130 may be asubstantially halogen free or halogen free layer to meet therestrictions on hazardous substances requirements for certainapplications. In other instances, one or more of the layers 110-130 maycomprise a halogenated flame retardant agent such as, for example, ahalogenated flame retardant that comprises one of more of F, Cl, Br, I,and At or compounds that including such halogens, e.g., tetrabromobisphenol-A polycarbonate or monohalo-, dihalo-, trihalo- ortetrahalo-polycarbonates. In some instances, the thermoplastic materialused in one or more of the layers 110-130 may comprise one or morehalogens to impart some flame retardancy without the addition of anotherflame retardant agent. Where halogenated flame retardants are present,the flame retardant is desirably present in a flame retardant amount,which can vary depending on the other components which are present. Forexample, the halogenated flame retardant may be present in about 0.1weight percent to about 15 weight percent (based on the weight of thelayer), more particularly about 1 weight percent to about 13 weightpercent, e.g., about 5 weight percent to about 13 weight percent. Ifdesired, two different halogenated flame retardants may be added to thelayers. In other instances, a non-halogenated flame retardant agent suchas, for example, a flame retardant agent comprising one or more of N, P,As, Sb, Bi, S, Se, and Te can be added. In some embodiments, thenon-halogenated flame retardant may comprise a phosphorated material sothe layers may be more environmentally friendly. Where non-halogenatedor substantially halogen free flame retardants are present, the flameretardant is desirably present in a flame retardant amount, which canvary depending on the other components which are present. For example,the substantially halogen free flame retardant may be present in about0.1 weight percent to about 15 weight percent (based on the weight ofthe layer), more particularly about 1 weight percent to about 13 weightpercent, e.g., about 5 weight percent to about 13 weight percent basedon the weight of the layer. If desired, two different substantiallyhalogen free flame retardants may be added to one or more of the layers110-130. In certain instances, one or more of the layers 110-130described herein may comprise one or more halogenated flame retardantsin combination with one or more substantially halogen free flameretardants. Where two different flame retardants are present, thecombination of the two flame retardants may be present in a flameretardant amount, which can vary depending on the other components whichare present. For example, the total weight of flame retardants presentmay be about 0.1 weight percent to about 20 weight percent (based on theweight of the layer), more particularly about 1 weight percent to about15 weight percent, e.g., about 2 weight percent to about 14 weightpercent based on the weight of the layer. The flame retardant agentsused in the layers described herein can be added to the mixturecomprising the thermoplastic material and fibers (prior to disposal ofthe mixture on a wire screen or other processing component) or can beadded after the layer is formed.

Several different illustrative layer assemblies are now described toillustrate further some of the possible configurations of a multi-layerassembly with variable lofting capacity. Additional configurations willbe recognized by the person of ordinary skill in the art, given thebenefit of this disclosure. Referring to FIG. 2, a composite article 200is shown comprising layers 210, 220 and 230. In this examples, layers220 and 230 are selected to be the same with a respective one of thelayers 220, 230 disposed on a surface of the layer 210. In theconfiguration shown in FIG. 2, the core layer 210 is selected such thatit has a higher lofting capacity than the layers 220, 230. Upon exposureto heat or other lofting stimulus, the post-loft thickness of the layer210 will be greater than that of the layers 220, 230. For example, thethickness of the layer 210 prior to lofting may be about 1-2 mm andafter lofting may be about 10-15 mm. The thickness of the layers 220,230 prior to lofting may also be about 1-2 mm and after lofting may beabout 6-8 mm. These thickness changes may occur even in the absence ofany added lofting agent. For example and without wishing to be bound byany particular theory, during lofting the thermoplastic material maymelt and release their hold on the reinforcing materials to permit thereinforcing materials to occupy more volume. Subsequent cooling of thethermoplastic material can result in reformation of a web of open celledstructures with a larger volume than the pre-lofted web. By tuning thelevel of thermoplastic material and/or reinforcing materials in thelayer 210, the degree to which the volume of the layer 210 can increasemay be selected. In comparison, the amount of thermoplastic materialand/or reinforcing materials present in the layers 220, 230 can beselected such that melting of the thermoplastic material during loftingdoes not result in a substantial increase in the overall volume. As theweb of the layers 220, 230 reforms after lofting, the resultingpost-lofted web volume is not substantially different from thepre-lofted web volume. If desired, one or more of the layers 210-230 mayinclude an added lofting agent to further increase the overall volume.For example, the layer 210 may comprise an added lofting agent tofurther select the overall post-lofted volume. In some instances, enoughlofting agent is present so the post-lofted layer 210 has a thickness ofabout 20-25 mm. In some examples, the layer 210 may comprise apolyolefin, reinforcing fibers and a lofting agent, and the layers 220,230 may comprise a polyolefin (which can be the same or different thanthe polyolefin in the layer 210) and a reinforcing material. In certainconfigurations, the polyolefin present in each of the layers 210-230 maybe polypropylene or a polyolefin copolymer comprising polypropylene. Insome embodiments, the reinforcing material of each of the layers 210-230may comprise glass fibers optionally in combination with other fibers.The exact weight percentages of the thermoplastic material andreinforcing materials in each of the layers 210-230 may vary, andillustrative weight percentages in the layers 220, 230 are about 40-60weight percent thermoplastic material with the balance being reinforcingmaterial. The weight percentages of materials present in the layer 210can vary and illustrative ranges include, but are not limited to, about45-65 weight percent thermoplastic material with the balance beingreinforcing material and optionally lofting agent (which is typicallypresent from 0.1 up to about 15 weight percent).

In certain examples, another configuration of a multi-layer assembly isshown in FIG. 3. An article 300 is shown as comprising layers 310, 320and 330. In this example, layers 320 and 330 are selected to be the samewith a respective one of the layers 320, 330 disposed on a surface ofthe layer 310. In the configuration shown in FIG. 3, the core layer 310is selected such that it has a lower lofting capacity than the layers320, 330. Upon exposure to heat or other lofting stimulus, the post-loftthickness of the layer 310 will be less than that of the layers 320,330. For example, the thickness of the layer 310 prior to lofting may beabout 1-2 mm and after lofting may be about 6-8 mm. The thickness of thelayers 320, 330 prior to lofting may also be about 1-2 mm and afterlofting may be about 10-15 mm. These thickness changes in the layers320, 330 may occur even in the absence of any added lofting agent. Forexample and without wishing to be bound by any particular theory, duringlofting the thermoplastic material of the layers 320, 330 may melt andrelease their hold on the reinforcing materials to permit thereinforcing materials to occupy more volume. Subsequent cooling of thethermoplastic material can result in reformation of a web of open celledstructures with a larger volume than the pre-lofted web. By tuning thelevel of thermoplastic material and/or reinforcing materials in thelayers 320, 330, the degree to which the volume of the layers 320, 330can increase may be selected. In comparison, the amount of thermoplasticmaterial and/or reinforcing materials present in the layer 310 can beselected such that melting of the thermoplastic material during loftingdoes not result in a substantial increase in the overall volume. As theweb of the layer 310 reforms after lofting, the resulting post-loftedweb volume is not substantially different from the pre-lofted webvolume. If desired, one or more of the layers 310-330 may include anadded lofting agent to further increase the overall volume. For example,one or both of the layers 320, 330 may comprise an added lofting agentto further select the overall post-lofted volume. In some instances,enough lofting agent is present so the post-lofted layers 320, 330 eachhave a thickness of about 20-25 mm. In some examples, the layer 310 maycomprise a polyolefin, and reinforcing fibers, and the layers 320, 330may comprise a polyolefin (which can be the same or different than thepolyolefin in the layer 310), a reinforcing material and a loftingagent. In some instances, only one of the layers 320, 330 comprises alofting agent. In certain configurations, the polyolefin present in eachof the layers 310-330 may be polypropylene or a polyolefin copolymercomprising polypropylene. In some embodiments, the reinforcing materialof each of the layers 310-330 may comprise glass fibers optionally incombination with other fibers. The exact weight percentages of thethermoplastic material and reinforcing materials in each of the layers310-330 may vary, and illustrative weight percentages in the layers 320,330 are about 45-65 weight % thermoplastic material with the balancebeing reinforcing material and optionally lofting agent (which istypically present from 0.1 up to about 15 weight percent). The weightpercentages of materials present in the layer 310 can vary andillustrative ranges include, but are not limited to, about 35-60 weightpercent thermoplastic material with the balance being reinforcingmaterial.

In certain embodiments, an additional configuration of a multi-layerassembly is shown in FIG. 4. An article 400 is shown as comprisinglayers 410, 420 and 430. In this example, each of the layers 410-430 hasa different lofting capacity. In one configuration of the illustrationshown in FIG. 4, the core layer 410 has the highest lofting capacityfollowed by the layer 420 and then the layer 430. In a differentconfiguration, the core layer 410 has the highest lofting capacityfollowed by the layer 430 and then the layer 420. In otherconfigurations, the layer 420 has the highest lofting capacity followedby the layer 410 and then the layer 430. In a different configuration,the layer 420 has the highest lofting capacity followed by the layer 430and then the layer 410. In some configurations, the layer 430 has thehighest lofting capacity followed by the layer 410 and then the layer420. In a different configuration, the layer 430 has the highest loftingcapacity followed by the layer 420 and then the layer 410. Upon exposureto heat or other lofting stimulus, the post-loft thickness of the layerwith the highest lofting capacity will be greater than the other layers.For example, the thickness of the layer with the highest loftingcapacity may be about 1-2 mm and after lofting may be about 10-15 mm or20-25 mm where a lofting agent is present. The thickness of the layerwith the second highest lofting capacity prior to lofting may also beabout 1-2 mm and after lofting may be about 6-8 mm. The thickness of thelayer with the lowest highest lofting capacity prior to lofting may alsobe about 1-2 mm and after lofting may be about 3-5 mm. By tuning thelevel of thermoplastic material and/or reinforcing materials in thevarious layers 410-440, the degree to which the volume of the layers canincrease may be selected. In some examples, each of the layers 410-430may comprise a polyolefin and reinforcing fibers. In certainconfigurations, the layer with the highest lofting capacity may alsocomprise a lofting agent. In some examples, the thermoplastic materialof each layer may be a polyolefin such as polypropylene, but the amountof polypropylene in each of the layers 410-430 may be different. In someembodiments, the reinforcing material of each of the layers 410-430 maycomprise glass fibers optionally in combination with other fibers. Theexact weight percentages of the thermoplastic material and reinforcingmaterials in each of the layers 410-430 may vary to provide the desiredlofting capacity in each of the layers 410-430.

In certain configurations, any one or more of the multi-layer assembliesdescribed herein may comprise a skin layer disposed on one of the otherlayers. Referring to FIG. 5A, an illustration is shown of an article 500that comprises layers 510-530 and a skin 540 disposed on the layer 520.If desired the skin could instead be disposed on the layer 530. Forillustration purposes, the layers 510-520 are shown as being configuredsimilar to those layers described in reference to FIG. 2, though any ofthe other multi-layered configurations described herein may also be usedwith a skin. If desired, an adhesive layer (not shown) may be presentbetween the layer 520 and the skin 540. The skin 540 may comprise, forexample, a film (e.g., thermoplastic film or elastomeric film), a frim,a scrim (e.g., fiber based scrim), a foil, a woven fabric, a non-wovenfabric or be present as an inorganic coating, an organic coating, or athermoset coating. In other instances, the skin 540 may comprise alimiting oxygen index greater than about 22, as measured per ISO 4589dated 1996. Where a thermoplastic film is present as (or as part of) theskin 540, the thermoplastic film may comprise at least one of poly(etherimide), poly(ether ketone), poly(ether-ether ketone), poly(phenylenesulfide), poly(arylene sulfone), poly(ether sulfone), poly(amide-imide),poly(1,4-phenylene), polycarbonate, nylon, and silicone. Where a fiberbased scrim is present as (or as part of) the skin 540, the fiber basedscrim may comprise at least one of glass fibers, aramid fibers, graphitefibers, carbon fibers, inorganic mineral fibers, metal fibers, metalizedsynthetic fibers, and metalized inorganic fibers. Where a thermosetcoating is present as (or as part of) the skin 540, the coating maycomprise at least one of unsaturated polyurethanes, vinyl esters,phenolics and epoxies. Where an inorganic coating is present as (or aspart of) the skin 540, the inorganic coating may comprise mineralscontaining cations selected from Ca, Mg, Ba, Si, Zn, Ti and Al or maycomprise at least one of gypsum, calcium carbonate and mortar. Where anon-woven fabric is present as (or as part of) the skin 540, thenon-woven fabric may comprise a thermoplastic material, a thermalsetting binder, inorganic fibers, metal fibers, metallized inorganicfibers and metallized synthetic fibers. If desired, the skin 540 mayalso comprise a lofting agent as well.

In some examples, a second skin may be present on an opposite surface ofthe multi-layer assembly. Referring to FIG. 5B, a second skin 560 isshown as being present on the article 550. If desired, an adhesive layer(not shown) may be present between the layer 530 and the skin 560. Theskins 540, 560 may independently comprise, for example, a film (e.g.,thermoplastic film or elastomeric film), a frim, a scrim (e.g., fiberbased scrim), a foil, a woven fabric, a non-woven fabric or be presentas an inorganic coating, an organic coating, or a thermoset coating. Inother instances, the skins 540, 560 may independently comprise alimiting oxygen index greater than about 22, as measured per ISO 4589dated 1996. Where a thermoplastic film is present as (or as part of) theskin 540, the thermoplastic film may comprise at least one of poly(etherimide), poly(ether ketone), poly(ether-ether ketone), poly(phenylenesulfide), poly(arylene sulfone), poly(ether sulfone), poly(amide-imide),poly(1,4-phenylene), polycarbonate, nylon, and silicone. Where a fiberbased scrim is present as (or as part of) one or both of the skins 540,560, the fiber based scrim may comprise at least one of glass fibers,aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers,metal fibers, metalized synthetic fibers, and metalized inorganicfibers. Where a thermoset coating is present as (or as part of) one orboth of the skins 540, 560, the coating may comprise at least one ofunsaturated polyurethanes, vinyl esters, phenolics and epoxies. Where aninorganic coating is present as (or as part of) one or both of the skins540, 560 the inorganic coating may comprise minerals containing cationsselected from Ca, Mg, Ba, Si, Zn, Ti and Al or may comprise at least oneof gypsum, calcium carbonate and mortar. Where a non-woven fabric ispresent as (or as part of) one or both of the skins 540, 560 thenon-woven fabric may comprise a thermoplastic material, a thermalsetting binder, inorganic fibers, metal fibers, metallized inorganicfibers and metallized synthetic fibers. If desired, one or both of theskins 540, 560 may also comprise a lofting agent as well.

In certain instances, a multi-layer assembly can comprise a decorativelayer disposed on a skin present in the multi-layer assembly. Referringto FIG. 6, an article 600 comprises layers 610-630, a skin 640 disposedon the layer 620 and a decorative layer 650 disposed on the skin 640. Asdescribed herein, one or more of the layers 610-630 may have a variablelofting capacity, e.g., different amounts of materials and/or thepresence of a lofting agent. The skin 640 may be any of the skinsdescribed in connection with the skin 540 of FIGS. 5A and 5B, e.g.,films, scrims, frims, foils, a woven fabric, a coating, etc. Thedecorative layer 650 may be formed, e.g., from a thermoplastic film ofpolyvinyl chloride, polyolefins, thermoplastic polyesters, thermoplasticelastomers, or the like. The decorative layer 650 may comprise a carpet,rubber or other aesthetic covering. The decorative layer 650 may also bea multi-layered structure that includes a foam core formed from, e.g.,polypropylene, polyethylene, polyvinyl chloride, polyurethane, and thelike. A fabric may be bonded to the foam core, such as woven fabricsmade from natural and synthetic fibers, organic fiber non-woven fabricafter needle punching or the like, raised fabric, knitted goods, flockedfabric, or other such materials. The fabric may also be bonded to thefoam core with a thermoplastic adhesive, including pressure sensitiveadhesives and hot melt adhesives, such as polyamides, modifiedpolyolefins, urethanes and polyolefins. The decorative layer 650 mayalso be produced using spunbond, thermal bonded, spun lace, melt-blown,wet-laid, and/or dry-laid processes.

In some embodiments, the various layers and components described hereinmay be disposed directly onto each other without any intervening layeror material to couple the components. For example, the layers may beadjacent to each other without the use of any adhesive to couple thelayers to each other. In instances where an adhesive is desirable, oneor more thermoplastic polymer adhesives may be used. For example, it maybe desirable to couple the skin layer or the decorative layer to theassembly using an adhesive. In some examples, the thermoplasticcomponent of the adhesive layer may comprise a thermoplastic polymersuch as, for example, a polyolefin such as a polyethylene or apolypropylene. In other instances, the thermoplastic polymer of theadhesive layer may comprise, polystyrene, acrylonitrylstyrene,butadiene, polyethyleneterephthalate, polybutyleneterephthalate,polybutylenetetrachlorate, and polyvinyl chloride, both plasticized andunplasticized, and blends of these materials with each other or otherpolymeric materials. Other suitable thermoplastic polymers for use inthe adhesive layer include, but are not limited to, polyarylene ethers,polycarbonates, polyestercarbonates, thermoplastic polyesters,polyimides, polyetherimides, polyamides,acrylonitrile-butylacrylate-styrene polymers, amorphous nylon,polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone,polyether sulfone, liquid crystalline polymers, poly(1,4 phenylene)compounds commercially known as PARMAX®, high heat polycarbonate such asBayer's APEC® PC, high temperature nylon, and silicones, as well asalloys and blends of these materials with each other or other polymericmaterials. If desired, the adhesive may also comprise some thermosettingmaterial including, but not limited to, epoxides, epoxy resins,polyesters, polyester resins, urethanes, polyurethanes,diallyl-phthalates, polymides, cyanate esters, polycyanurates andcombinations thereof.

In certain examples, the multi-layer assemblies described herein caninclude more than three layers, e.g., may include, four, five, six ormore layers which can be lofted where at least one of the layers has adifferent lofting capacity than another layer. Referring to FIG. 7, anarticle 700 comprises layers 710-740 with layers 710, 740 being the sameand layers 720, 730 being the same. In some instances, the loftingcapacity of the layers 710, 740 is higher than that of the layers 720,730, whereas in other configurations the lofting capacity of the layers720, 730 is higher than that of the layers 710, 740. Each of the layers710-740 can include a thermoplastic material and a reinforcing materialas noted herein in connection with other layers. If desired, the layerswith a higher lofting capacity may include a lofting agent or morelofting agent than the layers with a lower lofting capacity. While notshown a skin may be present on one or both surfaces of the article 700,and a decorative layer may also be present if desired.

Referring to FIG. 8, another configuration of an article 800 is shownthat comprises layers 810-840 with layers 810, 820 being the same andlayers 830, 840 being the same. In some instances, the lofting capacityof the layers 810, 820 is higher than that of the layers 830, 840,whereas in other configurations the lofting capacity of the layers 830,840 is higher than that of the layers 810, 820. Each of the layers810-840 can include a thermoplastic material and a reinforcing materialas noted herein in connection with other layers. If desired, the layerswith a higher lofting capacity may include a lofting agent or morelofting agent than the layers with a lower lofting capacity. While notshown a skin may be present on one or both surfaces of the article 800,and a decorative layer may also be present if desired.

Referring to FIG. 9, another configuration of an article 800 is shownthat comprises layers 810-850 with layers 910, 940 being the same andlayers 920, 930, 950 being the same. In some instances, the loftingcapacity of the layers 910, 940 is higher than that of the layers 920,930, 950, whereas in other configurations the lofting capacity of thelayers 920, 930, 950 is higher than that of the layers 910, 920. Each ofthe layers 910-940 can include a thermoplastic material and areinforcing material as noted herein in connection with other layers. Ifdesired, the layers with a higher lofting capacity may include a loftingagent or more lofting agent than the layers with a lower loftingcapacity. While not shown a skin may be present on one or both surfacesof the article 900, and a decorative layer may also be present ifdesired.

In some embodiments, the layers may include additional materials oradditives to impart desired physical or chemical properties. Forexample, one or more dyes, texturizing agents, colorants, viscositymodifiers, smoke suppressants, synergistic materials, lofting agents,particles, powders, biocidal agents, foams or other materials can bemixed with or added to the prepregs or the cores. In some instances, thelayers may comprise one or more smoke suppressant compositions in theamount of about 0.2 weight percent to about 10 weight percent.Illustrative smoke suppressant compositions include, but are not limitedto, stannates, zinc borates, zinc molybdate, magnesium silicates,calcium zinc molybdate, calcium silicates, calcium hydroxides, andmixtures thereof. If desired, a synergist material can be present toenhance the physical properties of the prepregs or cores. If desired, asynergist material that enhances lofting ability may be present.Illustrative synergist materials include, but are not limited to, sodiumtrichlorobenzene sulfonate potassium, diphenyl sulfone-3-sulfonate, andmixtures thereof.

In certain examples, each of the layers of the multi-layer assembly canbe separately produced and then combined together to form themulti-layer assembly or layers may be formed on each other to build up amulti-layer assembly. For example, each of the layers may be separatelyproduced in a wet laid or other process and then combined together toprovide the multi-layer assembly. In producing the various layersdescribed herein, it may be desirable to use a wet-laid process. Forexample, a liquid or fluid medium comprising dispersed material, e.g.,thermoplastic materials, fibers and optionally lofting agent materialoptionally with any one or more additives described herein (e.g., otherlofting agents or flame retardant agents), may be stirred or agitated inthe presence of a gas, e.g., air or other gas. The dispersion may thenbe laid onto a support, e.g., a wire screen or other support material.The stirred dispersion may comprise one or more active agents, e.g.,anionic, cationic, or non-ionic such as, for example, those sold underthe name ACE liquid by Industrial Soaps Ltd., that sold as TEXOFOR® FN15 material, by Glover Chemicals Ltd., and those sold as AMINE Fb 19material by Float-Ore Ltd. These agents can assist in dispersal of airin the liquid dispersion. The components can be added to a mixing tank,flotation cell or other suitable devices in the presence of air toprovide the dispersion. While an aqueous dispersion is desirably used,one or more non-aqueous fluids may also be present to assist indispersion, alter the viscosity of the fluid or otherwise impart adesired physical or chemical property to the dispersion or the layer.

In certain instances, after the dispersion has been mixed for asufficient period, the fluid with the suspended materials can bedisposed onto a screen, moving wire or other suitable support structureto provide a web of laid down material. Suction or reduced pressure maybe provided to the web to remove any liquid from laid down material toleave behind the thermoplastic material, lofting agent and any othermaterials that are present, e.g., fibers, additives, etc. The resultingweb can be dried, consolidated, pressed, lofted, laminated, sized orotherwise processed further to provide a desired layer or article. Insome instances, an additive or additional lofting agent material can beadded to the web prior to drying, consolidation, pressing, lofting,laminating, sizing or other further processing to provide a desiredlayer or article. In other instances, the lofting agent may be added tothe web subsequent to drying, consolidation, pressing, lofting,laminating, sizing or other further processing to provide a desiredlayer or article. While wet laid processes may be used, depending on thenature of the thermoplastic material, the lofting agent material andother materials present, it may be desirable to instead use an air laidprocess, a dry blend process, a carding and needle process, or otherknown process that are employed for making non-woven products.

In some configurations, the layers described herein can be produced bycombining a thermoplastic material, fibers, and an optional microspherelofting agent in the presence of a surfactant in an aqueous solution orfoam. The combined components can be mixed or agitated for a sufficienttime to disperse the various materials and provide a substantiallyhomogeneous aqueous mixture of the materials. The dispersed mixture isthen laid down on any suitable support structure, for example, a wiremesh or other mesh or support having a desired porosity. Water can thenbe evacuated through the wire mesh forming a web. The web is dried andheated above the softening temperature of the thermoplastic powder. Theweb is then cooled and pressed to a predetermined thickness to produce acomposite sheet having a void content of between about 1 percent toabout 95 percent. In an alternate embodiment, the aqueous foam alsoincludes a binder material. In some configurations, after the web isheated above the softening temperature of the thermoplastic powder, anadhesive layer comprising a thermoplastic polymer and a thermosettingmaterial can then be disposed on the web.

In certain examples, one or more of the layers can be produced in theform of a GMT. In certain instances, the GMT can be generally preparedusing chopped glass fibers, a thermoplastic material, lofting agent andan optional thermoplastic polymer film or films and/or woven ornon-woven fabrics made with glass fibers or thermoplastic resin fiberssuch as, for example, polypropylene (PP), polybutylene terephthalate(PBT), polyethylene terephthalate (PET), polycarbonate (PC), a blend ofPC/PBT, or a blend of PC/PET. In some embodiments, a PP, a PBT, a PET, aPC/PET blend or a PC/PBT blend can be used as a resin. To produce theglass mat, a thermoplastic material, reinforcing materials, loftingagent and/or other additives can be added or metered into a dispersingfoam contained in an open top mixing tank fitted with an impeller.Without wishing to be bound by any particular theory, the presence oftrapped pockets of air of the foam can assist in dispersing the glassfibers, the thermoplastic material and the lofting agent. In someexamples, the dispersed mixture of glass and resin can be pumped to ahead-box located above a wire section of a paper machine via adistribution manifold. The foam, not the glass fiber, lofting agent orthermoplastic, can then be removed as the dispersed mixture is providedto a moving wire screen using a vacuum, continuously producing auniform, fibrous wet web. The wet web can be passed through a dryer at asuitable temperature to reduce moisture content and to melt or softenthe thermoplastic material. When the hot web exits the dryer, a surfacelayer such as, for example, an adhesive layer comprising a thermoplasticpolymer and a thermosetting material may be laid onto the web by passingthe web of glass fiber, lofting agent, thermoplastic material and filmthrough the nip of a set of heated rollers followed by spraying of theadhesive onto the surface of the web. If desired, additional layers suchas, for example, a non-woven and/or woven fabric layer or skin layer mayalso be attached to one side or to both sides of the web to facilitateease of handling the glass fiber-reinforced mat. The composite can thenbe passed through tension rolls and continuously cut (guillotined) intothe desired size for later forming into an end product article. Furtherinformation concerning the preparation of such GMT composites, includingsuitable materials and processing conditions used in forming suchcomposites, are described, for example, in U.S. Pat. Nos. 6,923,494,4,978,489, 4,944,843, 4,964,935, 4,734,321, 5,053,449, 4,925,615,5,609,966 and U.S. Patent Application Publication Nos. US 2005/0082881,US2005/0228108, US 2005/0217932, US 2005/0215698, US 2005/0164023, andUS 2005/0161865.

In some instances, each of the layers may be formed separately as asheet which is then used to provide a multi-layer article. For example,a wet laid process can be used to produce a first sheet with a lowlofting capacity. A wet laid process can also be used to produce asecond sheet with a higher lofting capacity than the first sheet. Eachsheet may be processed prior to coupling to each other. For example,each sheet may be compressed to provide for a desired thickness. Two ofthe first sheets can be coupled to the second sheet to provide a 3-layerassembly similar to that shown in FIG. 2. While the coupling process mayvary, in some instances, one first sheet is heated to a temperaturewhere the thermoplastic component softens. The second sheet is thendisposed on the heated first sheet and additional heating is applied tosoften the disposed second sheet. Another first sheet is then disposedon the heated, disposed second sheet with heating. The three layers“melt” together to couple the layers to each other. Pressure and/ortemperature may be applied using processed such as molding,thermoforming, etc. to assist in coupling the sheets to each other. Inother instances, one sheet may be formed onto another sheet by disposingthe material onto the sheet in a liquid slurry form and permitting thewater to evaporate leaving behind the thermoplastic material andreinforcing materials. Once the slurry cures, an additional sheet may beformed on top of the cured sheet using similar methods.

The articles described herein can be processed into a desiredconfiguration or shape using suitable processes including, but notlimited to, molding, thermoforming, drawing or other forming processes.In some instances, such processes are used to impart a desiredconfiguration and/or to loft the various layers of the article. Forexample, where the article is designed to function as a vehicle floor,the floor may be shaped and/or cut in a desired manner. Referring toFIG. 10, a vehicle floor 1000 is shown as being disposed and coupled toa vehicle frame comprising components 1005 a, 1005 b. The floor 1000 isa generally planar structure comprising one or more of the multi-layerassemblies described herein, e.g., those shown and described inconnection with FIGS. 1-9, or other similar multi-layer assemblies thatwill be selected by the person of ordinary skill in the art, given thebenefit of this disclosure. The floor 1000 may be coupled to the framethrough suitable fasteners such as bolts, screws and the like andoptionally with one or more adhesives. In some instances, doors, a roofassembly and other components of the vehicle may be disposed onto thefloor 1000 to provide a user cabin. If desired, a carpet, foam padding,and the like may be coupled to the floor 1000 for aesthetic or otherreasons.

In some embodiments, a load floor for a rear storage compartment may beproduced using the articles described herein. Referring to FIG. 11, aside view of a deep drawn article 1100 that can be used as a load flooris shown. The article 1100 is typically positioned in the rear portionof the vehicle, e.g., a rear storage portion of a sport utility vehicleor minivan, and is designed to receive components, gear, luggage, aspare tire, etc. for storage. A lid or covering (not shown) may also bepresent to enclose the components within the load floor 1100 and shieldthem from view. The load floor 1100 may comprise, for example, any ofthe multi-layer assemblies described herein, e.g., those shown anddescribed in connection with FIGS. 1-9, or other similar multi-layerassemblies that will be selected by the person of ordinary skill in theart, given the benefit of this disclosure.

In some embodiments, the load floor can include structural members orslats to provide additional strength if desired. For example, one, two,three or more metal bars or members can be positioned within the loadfloor, e.g., in the core layer or in any other layer, to provide foradditional strength. As described in more detail in the examples below,certain configurations of a load floor may provide no more than adesired amount of deflection under a selected weight, e.g., as testedusing ASTM D790-10 dated Apr. 1, 2010. If a particular load floorconstruction deflects more than a desired amount, e.g., no more than 10mm of deflection under a 100 kg load, then the core layer or the otherlayers can be altered, e.g., by altering the materials and/or byincluding structural members, to provide a load floor that meet adesired specification.

In some embodiments, the articles described herein may be configured inthe form of a vehicle exterior or hull, e.g., a recreational vehicleexterior panel, a boat hull or other structural panels that may need towithstand some weight or force. The panels are particular desirable foruse in higher humidity environments as the core layers are not generallysensitive to water exposure and the properties do not change to asubstantial degree upon exposure to water.

In certain examples, the exact nature of the core layer and the otherlayers selected may depend, at least in part, on the desired acousticproperties of the article including the various layers. For example,certain configurations of the core layers described herein can provideexcellent sound absorption but may not have desired sound barrierproperties. A skin or other layer can be selected whose acousticproperties complement that of the core layer to provide a compositestructure with good sound absorption and sound barrier properties.

In some embodiments, the core layer of the articles described herein canbe water resistant. For example, in many configurations of a load floor,the core layer may be a paper based material. Exposure of the paperbased material to water can greatly reduce the core layer strength andcan promote mold growth. By using a core layer as described herein,water exposure does not alter the overall strength of the article.

Certain examples are described below to illustrate better some of thenovel aspects and configurations described herein.

Example 1

A vehicle load floor was produced using a Superlite™ material (availablefrom Hanwha Azdel, Inc.) as a skin and a polyurethane foam block (6pounds per cubic feet). The Superlite™ material was present on both sideof the polyurethane foam block. The overall panel thickness was 21.5 mm,the panel weight was about 5332 gsm and the panel density was 0.24g/cm³. Under a 45 kg load (using a support width of 815 mm and a supportlength of 380 mm), a deflection of 1.8 mm was observed (or 0.34 mm/1000gsm mass). At a 60 kg load, the deflection was 2.39 mm. In this Example1 and the examples below, a coupon of the load floor was placed onto thesupport of specified dimensions, and a weight was placed on the span.The distance of deflection was then measured.

Example 2

Deflection values for several comparative load floors were measured tocompare to Example 1. A first load floor and a second load floor eachincluded a glass fiber reinforced polyurethane skin material and a paperhoneycomb core layer. The first load floor (Comparative Load Floor #1)was 20 mm thick, weighed about 3235 gsm and had a board density of about0.14 g/cm³. The second load floor (Comparative Load Floor #2) was about16.6 mm thick, weighed about 3950 gsm and had a board density of about0.25 g/cm³. A third load floor was also produced using a polypropyleneblow molding process to produce a skin. The third load floor(Comparative Load Floor #3) was hollow and included a thickness of 18.6mm, a weight of 5520 gsm and a board density of 0.3 g/cm³. Thedeflection results under the same 45 kg load, 60 kg load and loadconditions of Example 1 are shown in Table 1.

TABLE 1 Deflection Deflection Deflection under 45 per 1000 under 60 LoadFloor kg (mm) gsm Mass (mm) kg (mm) Comparative Load 2.8 0.87 3.35 Floor#1 Comparative Load 2.31 0.51 2.9 Floor #2 Comparative Load 11.5 2.114.5 Floor #3In comparing the results in Table 1 to those of Example 1, lessdeflection was observed in the Example 1 load floor compared to any ofthe comparative load floors. In addition, the deflection/1000 gsm massof the Example 1 load floor was about over 30% less than the next bestcomparative load floor

Example 3

Heat cycling was performed on coupons (3 inches in width and 14 inchesin length) cut from each of three of the loads floors of Example 1 and 2(Example 1 load floor and Comparative Load Floors #1 and #2). The testconditions used were 95+/−3% relative humidity at 40+/−2 deg. C. for 18hours. A 10 kg weight was then placed on each coupon. The coupon fromthe load floor of Example 1 withstood the 10 kg weight with minimaldeflection. The coupons from comparative load floors #2 and #3 bothfailed (broke) under the 10 kg weight.

Example 4

The coupon from load floor of Example 1 was tested under heavier weightto measure the deflection. At 220 kg, the deflection was measured to be3.1 mm. After removal of the 220 kg weight, the coupon of the load floorexhibited a permanent deflection of about 0.1 mm (similar to thepermanent deflection that occurred using the other weights in Examples1-3).

Example 5

A composite panel is produced by combining two Superlite™ skins with anXL4 core (a polypropylene/glass fiber material), each of which iscommercially available from Hanwha Azdel, Inc. (Forest, Va.). The weightof the Superlite™ skins varies from about 500 gsm to about 3000 gsm, andthe weight of the XL4 core layer varies from about 500 gsm to about 1600gsm. The weight of the Superlite™ skins on each side of the XL4 corelayer is about the same. The exact dimensions may vary and illustrativeoverall dimensions include a length of about 18 inches to about 36inches, a width of about 8 inches to about 22 inches and a thickness ofabout 6 mm to about 50 mm.

Example 6

A composite panel is produced by combining two Superlite™ skins with anXL4 core (all commercially available from Hanwha Azdel, Inc.). Theweight of the Superlite™ skins varies from about 500 gsm to about 3000gsm, and the weight of the XL4 core layer varies from about 500 gsm toabout 1600 gsm. The weight of one Superlite™ skin on one side of the XL4core is different than a weight of the other Superlite™ skin on theother side of the XL4 core layer. The exact dimensions may vary andillustrative overall dimensions include a length of about 18 inches toabout 36 inches, a width of about 8 inches to about 22 inches and athickness of about 6 mm to about 50 mm.

Example 7

A composite panel is produced by combining two Superlite™ skins with anXL4 core (all commercially available from Hanwha Azdel, Inc.). Theweight of the Superlite™ skins varies from about 500 gsm to about 3000gsm, and the weight of the XL4 core layer varies from about 500 gsm toabout 1600 gsm. The weight of one Superlite™ skin on one side of the XL4core is the same or different than a weight of the other Superlite™ skinon the other side of the XL4 core layer. A decorative layer, e.g., anon-woven fabric, is added to at least one of the Superlite™ skins. Theexact dimensions may vary and illustrative overall dimensions include alength of about 18 inches to about 36 inches, a width of about 8 inchesto about 22 inches and a thickness of about 6 mm to about 50 mm.

Example 8

A composite panel is produced by combining two Superlite™ skins with anXL4 core comprising expandable microsphere lofting agents, each of whichis commercially available from Hanwha Azdel, Inc. (Forest, Va.). Theweight of the Superlite™ skins varies from about 500 gsm to about 3000gsm, and the weight of the XL4 core layer varies from about 500 gsm toabout 1600 gsm. The weight of the Superlite™ skins on each side of theXL4 core layer is about the same. The exact dimensions may vary andillustrative overall dimensions include a length of about 18 inches toabout 36 inches, a width of about 8 inches to about 22 inches and athickness of about 6 mm to about 50 mm.

Example 9

A composite panel is produced by combining two Superlite™ skins with anXL4 core comprising expandable microsphere lofting agents (allcommercially available from Hanwha Azdel, Inc.). The weight of theSuperlite™ skins varies from about 500 gsm to about 3000 gsm, and theweight of the XL4 core layer varies from about 500 gsm to about 1600gsm. The weight of one Superlite™ skin on one side of the XL4 core isdifferent than a weight of the other Superlite™ skin on the other sideof the XL4 core layer. The exact dimensions may vary and illustrativeoverall dimensions include a length of about 18 inches to about 36inches, a width of about 8 inches to about 22 inches and a thickness ofabout 6 mm to about 50 mm.

Example 10

A composite panel is produced by combining two Superlite™ skins with anXL4 core comprising expandable microsphere lofting agents (allcommercially available from Hanwha Azdel, Inc.). The weight of theSuperlite™ skins varies from about 500 gsm to about 3000 gsm, and theweight of the XL4 core layer varies from about 500 gsm to about 1600gsm. The weight of one Superlite™ skin on one side of the XL4 core isthe same or different than a weight of the other Superlite™ skin on theother side of the XL4 core layer. A decorative layer, e.g., a non-wovenfabric, is added to at least one of the Superlite™ skins. The exactdimensions may vary and illustrative overall dimensions include a lengthof about 18 inches to about 36 inches, a width of about 8 inches toabout 22 inches and a thickness of about 6 mm to about 50 mm.

When introducing elements of the examples disclosed herein, the articles“a,” “an,” “the” and “said” are intended to mean that there are one ormore of the elements. The terms “comprising,” “including” and “having”are intended to be open-ended and mean that there may be additionalelements other than the listed elements. It will be recognized by theperson of ordinary skill in the art, given the benefit of thisdisclosure, that various components of the examples can be interchangedor substituted with various components in other examples.

Although certain aspects, examples and embodiments have been describedabove, it will be recognized by the person of ordinary skill in the art,given the benefit of this disclosure, that additions, substitutions,modifications, and alterations of the disclosed illustrative aspects,examples and embodiments are possible.

1-60. (canceled)
 61. A method of forming a thermoplastic sheetcomprising: forming a core layer by: combining a thermoplastic polymer,reinforcing fibers and a lofting agent in an aqueous solution; mixingthe aqueous solution comprising the thermoplastic polymer, reinforcingfibers and lofting agent to disperse the reinforcing fibers and thelofting agent in the thermoplastic polymer to provide an aqueous foamdispersion; disposing the aqueous foam dispersion onto a formingelement; removing liquid from the disposed aqueous foam to provide acore layer comprising a web comprising the thermoplastic polymer, thereinforcing fibers and the lofting agent; forming a first layer by:combining a thermoplastic polymer, reinforcing fibers and a loftingagent in an aqueous solution; mixing the aqueous solution comprising thethermoplastic polymer, reinforcing fibers and lofting agent to dispersethe reinforcing fibers and the lofting agent in the thermoplasticpolymer to provide an aqueous foam dispersion; disposing the aqueousfoam dispersion onto a forming element; removing liquid from thedisposed aqueous foam to provide a first layer comprising a webcomprising the thermoplastic polymer, the reinforcing fibers and thelofting agent; disposing the formed first layer on a first surface ofthe core layer; and disposing another first layer on a second surface ofthe core layer to provide a thermoplastic sheet.
 62. The method of claim61, further comprising heating the core layer above a softeningtemperature of the thermoplastic polymer of the web of the core layerprior to disposing the first layer on the first surface of the corelayer.
 63. The method of claim 62, further comprising heating the corelayer above a softening temperature of the thermoplastic polymer of theweb of the core layer prior to disposing the first layer on the secondsurface of the core layer.
 64. The method of claim 61, furthercomprising disposing an adhesive layer on the first surface of the corelayer prior to disposing the first layer on the first surface.
 65. Themethod of claim 61, further comprising disposing an adhesive layer onthe first layer prior to disposing the first layer on the first surface.66. The method of claim 65, further comprising disposing an adhesivelayer on the second surface of the core layer prior to disposing thefirst layer on the second surface.
 67. The method of claim 65, furthercomprising disposing an adhesive layer on the first layer prior todisposing the first layer on the second surface.
 68. The method of claim61, further comprising heating the thermoplastic sheet to loft each ofthe core layer and the first layers.
 69. The method of claim 68, furthercomprising selecting a first loft temperature to loft the first layerswhere the first layer lacks any lofting agent.
 70. The method of claim69, further comprising selecting a second loft temperature to loft thecore layer.
 71. The method of claim 69, further comprising selecting thefirst loft temperature to loft the first layer without any substantialloft of the core layer.
 72. The method of claim 61, further comprisingdisposing a decorative layer on one of the first layers.
 73. The methodof claim 61, further comprising lofting the first layers disposed on thecore layer using radiant heating or conduction heating.
 74. The methodof claim 73, further comprising lofting the core layer using infraredheating.
 75. The method of claim 61, further comprising compressing thethermoplastic sheet to reduce its overall thickness.
 76. The method ofclaim 75, further comprising molding the compressed thermoplastic sheet.77. The method of claim 71, further comprising compressing the corelayer prior to disposing the first layers on the core layer.
 78. Themethod of claim 77, further comprising compressing the first layersprior to disposing the first layers on the core layer.
 79. The method ofclaim 71, further comprising disposing a skin layer on the first layerdisposed on the first surface of the core layer.
 80. The method of claim79, further comprising disposing an additional skin layer on the firstlayer disposed on the second surface of the core layer. 81-120.(canceled)